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Yamaha YFM80GV Owner's Manual

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OWNER'S MANUAL
YFM80GV
2D3-28199-20

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Summary of Contents for Yamaha YFM80GV

  • Page 1 OWNER’S MANUAL YFM80GV 2D3-28199-20...
  • Page 3 Congratulations on your purchase of the BEFORE OPERATING YOUR MACHINE. Yamaha YFM80G. It represents the result of MAKE SURE YOU UNDERSTAND ALL many years of Yamaha experience in the pro- INSTRUCTIONS. duction of fine sporting, touring, and pacesetting 8 PAY CLOSE ATTENTION TO THE WARN- racing machines.
  • Page 4 Your ATV was delivered with an adjustable speed limiter and also with an air intake restric- tor plate. Yamaha recommends that all begin- ners start off with the speed limiter screw turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn.
  • Page 5 YFM80GV could result in severe injury or death to the OWNER’S MANUAL machine operator, a bystander or a person ©2005 by Yamaha Motor Co., Ltd. inspecting or repairing the machine. 1st edition, March 2005 All rights reserved. Any reprinting or...

  • Page 6: Table Of Contents

    EBU00015 CONTENTS LOCATION OF THE WARNING AND Parking brake ........4-6 SPECIFICATION LABELS .......1-1 Shift pedal ..........4-7 Fuel tank cap ........4-8 SAFETY INFORMATION ......2-1 Fuel cock ..........4-8 Choke lever ..........4-9 DESCRIPTION AND MACHINE Seat ............4-9 IDENTIFICATION........3-1 Carrier ..........4-10 Identification number records ....3-2 Key identification number .....3-2 PRE-OPERATION CHECKS ....5-1 Vehicle identification number ....3-3...
  • Page 7 OPERATION ..........6-1 Crossing through shallow water ..7-21 Starting a cold engine......6-1 Riding over rough terrain ....7-23 Starting a warm engine ......6-3 Sliding and skidding ......7-23 Warming up ..........6-3 What to do if ........7-25 Shifting ..........6-4 What to do .........7-25 To start out and accelerate....6-5 To decelerate ........6-6 PERIODIC MAINTENANCE AND Engine break-in ........6-6...
  • Page 8 Front brake lever free play CLEANING AND STORAGE....9-1 adjustment ........8-17 A. Cleaning ...........9-1 Rear brake lever and pedal B. Storage ..........9-2 adjustment ........8-19 Adjusting the clutch ......8-21 SPECIFICATIONS .........10-1 Cable inspection and lubrication ..8-22 Brake and shift pedal/brake lever lubrication ........8-22 Conversion Table ........11-1 Knuckle shaft and steering shaft lubrication .........8-22...

  • Page 9: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label available from your Yamaha dealer.
  • Page 10 WARNING WARNING Improper ATV use can result in SEVERE UNDER INJURY or DEATH. Operating this ATV if you are under the age of 12 increases your chance of severe injury or death. ALWAYS USE NEVER USE NEVER CARRY NEVER USE Adult supervision required for children AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS...
  • Page 11 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN NEVER ride as a CAUSE LOSS OF CONTROL. passenger. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. Passengers can cause OPERATING TIRE PRESSURE: Set with tires cold 9Recommended : FRONT : 20 kPa, { 0.20 kgf/cm } 2.9 psi a loss of control, REAR : 20 kPa, { 0.20 kgf/cm...
  • Page 12 5kg 11lbs 3LD-24877-A0 NEVER sit here. 3MX-24875-A0...

  • Page 13: Safety Information

    EBU10421 8 Never allow a child under age 16 to operate SAFETY INFORMATION an ATV without adult supervision, and never allow continued use of an ATV by a child if he AN ATV IS NOT A TOY AND CAN BE HAZ- or she does not have the abilities to operate it ARDOUS TO OPERATE.
  • Page 14 8 Never operate at speeds too fast for your 8 Never operate on excessively rough, slippery skills or the conditions. Always go at a speed or loose terrain until you have learned and that is proper for the terrain, visibility and practiced the skills necessary to control the operating conditions, and your experience.
  • Page 15 8 Always follow proper procedures for going 8 Always use proper procedures if you stall or down hills and for braking on hills as roll backwards when climbing a hill. To avoid described in this manual. Check the terrain stalling, use proper gear and maintain a carefully before you start down any hill.
  • Page 16 8 Never operate an ATV in fast flowing water or 8 Never exceed the stated load capacity for an in water deeper than that recommended in ATV. Cargo should be properly distributed this manual. Remember that wet brakes may and securely attached. Reduce speed and fol- have reduced stopping ability.
  • Page 17 Always operate your ATV in an area with adequate ventilation. Never start or run the engine in a closed area. Exhaust fumes are poisonous and may cause loss of con- sciousness and death within a short time. 8 When transporting the machine in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF”...

  • Page 18: Description And Machine Identification

    EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Carrier 10. Rear brake lever 2. Seat 11. Parking brake 3. Front cover 12. Neutral indicator light 4. Brake pedal 13. Front brake lever 5. Fuel cock 14. Throttle lever 6. Rear wheel 15. Main switch 7.

  • Page 19: Identification Number Records

    This tion in the spaces provided for assistance when number can be used for ordering a new key. ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2.

  • Page 20: Vehicle Identification Number

    The model label is affixed to the location in the into the frame. illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha NOTE: dealer. The vehicle identification number is used to identify your machine.

  • Page 21: Control Functions

    EBU00040 EBU00043 Indicator lights CONTROL FUNCTIONS EBU00603 EBU00042 Neutral indicator light “N” Main switch This indicator light comes on when the transmis- Functions of the respective switch positions are sion is in neutral. as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off.

  • Page 22: Handlebar Switches

    EBU00053 EBU00056 Handlebar switches Start switch “START” The starter motor cranks the engine when this EBU11580 Engine stop switch “ENG. STOP” switch is pushed. Make sure that the engine stop switch is in the “RUN” position before starting the engine. The engine stop switch controls ignition and can be See starting instructions prior to starting used at all times to stop the engine, especially in...

  • Page 23: Throttle Lever

    This could cause an accident. Check the operation of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem before riding the ATV or consult a Yamaha dealer.

  • Page 24: Speed Limiter

    1. Locknut 2. Adjuster tor plate. Yamaha recommends that all begin- a. No more than 20 mm ners start off with the speed limiter screw turned Since removal of this plate will result in a signifi-...

  • Page 25: Front Brake Lever

    EBU00070 Front brake lever The front brake lever is located on the right han- Improper adjustment of the speed limiter and dlebar. Pull it toward the handlebar to apply the throttle could cause throttle cable damage or front brake. improper throttle operation. You could lose control, have an accident or be injured.

  • Page 26: Brake Pedal And Rear Brake Lever

    EBU00732 EBU00075 Brake pedal and rear brake lever Parking brake The brake pedal is located on the right side of Use the parking brake when you have to start the ATV and the rear brake lever is located on the engine or park the machine, especially on a the left handlebar.

  • Page 27: Shift Pedal

    EBU00083 Shift pedal This machine is equipped with a constant-mesh 3-speed transmission. The shift pedal is located on the left side of the engine. Neutral is at the bottom position. 1. Locked position 8 Always set the parking brake before start- ing the engine.

  • Page 28: Fuel Tank Cap

    EBU00092 EBU00093 Fuel tank cap Fuel cock Remove the fuel tank cap by turning it counter- The fuel cock supplies fuel from the fuel tank to clockwise. the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow.

  • Page 29: Choke Lever

    EBU00096 EBU00566 Choke lever Seat The choke is used to start a cold engine. Refer To remove the seat, pull the seat lock lever to “Starting a cold engine” for proper operation. upward and pull up the seat at the rear. (See page 6-1.) 1 2 3 1.

  • Page 30: Carrier

    1. Projection 2. Seat holder EBU15680 Carrier Maximum load limit: 5 kg 4-10...

  • Page 31: Pre-Operation Checks

    EBU00113 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE 9 Check operation, condition and free play. Brakes 5-3, 8-16–8-20 9 Adjust if necessary. 9 Check fuel level. Fuel 9 Fill with fuel if necessary. 9 Check oil level. Engine oil 5-5, 8-5–8-6 9 Fill with oil if necessary.
  • Page 32 Always inspect your ATV each time you use it to make sure the ATV is in safe operating condi- tion. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. Failure to inspect increases the possibility of an accident or equipment dam- age.

  • Page 33: Front And Rear Brakes

    8 Check operation of the brake levers and adjustment procedures provided in this man- brake pedal. They should move smoothly and ual, have the ATV inspected by a Yamaha there should be a firm feeling when the dealer. brakes are applied. If not, have the ATV inspected by a Yamaha dealer.

  • Page 34: Fuel

    EBU09981* Fuel Make sure there is sufficient gasoline in the 8 Do not overfill the fuel tank. Fuel expands tank. when it heats up. If the fuel tank is over- filled, fuel could spill out due to heat from Recommended fuel: the engine or the sun.

  • Page 35: Engine Oil

    EBU10842 EBU00493 Final gear oil Engine oil Make sure the final gear oil is at the specified Make sure the engine oil is at the specified level. level. Add oil as necessary. (See pages 8-7– Add oil as necessary. (See page 8-5–8-6.) 8-8 for details.) 8 In order to prevent clutch slippage (since Recommended oil:...

  • Page 36: Throttle Lever

    Check to see that the throttle lever operates cor- Always use the recommended tires. rectly. It must open smoothly and spring back to the idle position when released. Have a Yamaha Use of improper tires on this ATV, or opera- dealer repair as necessary for proper operation.

  • Page 37: How To Measure Tire Pressure

    EBU14450 8 Check and adjust tire pressures when How to measure tire pressure the tires are cold. Use the low-pressure tire gauge. 8 Tire pressures must be equal on both sides. 3. Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge The low-pressure tire gauge is included as stan- from the rim under severe riding condi- dard equipment.

  • Page 38: Tire Wear Limit

    Tire wear limit EBU11620 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service 1. Low-pressure tire gauge Manual for correct tightening torque.

  • Page 39: Switches

    EBU11700 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. EBU00499 Battery Check fluid level and fill if necessary. Use only distilled water if refilling is necessary. (See pages 8-24–8-25.)

  • Page 40: Operation

    If there is a control or function you do not understand, ask your Yamaha dealer. 1. Set the parking brake. 2. Turn the fuel cock to “ON”. 3. Turn the main switch to “ON” and the engine stop switch to “RUN”.
  • Page 41 When the transmission is in neutral. At this time the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. b. When the transmission is in gear and the rear brake lever is applied. However, it is 1.

  • Page 42: Starting A Warm Engine

    EBU00181 7. If the engine is started with the starter Starting a warm engine (choke) in position 1, the choke lever To start a warm engine, refer to the “Starting a should be returned to position 2 to warm cold engine” section. The choke lever should not up the engine.

  • Page 43: Shifting

    EBU00200 Shifting This model has a 3-speed forward transmission Do not coast for long periods with the engine with centrifugal automatic clutch. The transmis- off, and do not tow the machine a long dis- sion allows you to control the amount of power tance.

  • Page 44: To Start Out And Accelerate

    EBU00650 To start out and accelerate: 1. Release the throttle lever. Always open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the machine wheelie or overturn. Always close the throttle while shifting gears.

  • Page 45: To Decelerate

    EBU00208 EBU02092 To decelerate: Engine break-in When slowing down or stopping, release the There is never a more important period in the throttle and apply the brakes smoothly and life of your machine than the period between evenly. As you slow down, shift to a lower gear. zero and 20 hours.

  • Page 46: Parking

    EBU15690 If any abnormality is noticed during this period, Parking consult a Yamaha dealer. When parking, stop the engine and shift into the forward position. Turn the fuel cock to “OFF” 0-10 hours: and apply the parking brake. Avoid continuous operation above half throttle.

  • Page 47: Parking On A Slope

    EBU02201 Parking on a slope Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, put the ATV in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects.

  • Page 48: Accessories And Loading

    8 Use extra caution when riding an ATV with However, it is not possible for Yamaha to test accessories. The ATV may handle differently all non-Yamaha accessories, nor have any than it does without accessories.
  • Page 49 EBU15571 8 Make sure the load does not interfere with Loading controls or your ability to see where you are This ATV is not designed to tow a trailer. If you going. choose to add accessories so that you can tow 8 Ride more slowly than you would without a a trailer, you must use common sense and good load.
  • Page 50 Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or towing cargo improperly could cause changes in vehicle handling which could lead to an accident. Cargo should be properly distributed and securely attached. Reduce speed when car- rying cargo or pulling a trailer.

  • Page 51: Riding Your Atv

    Riding Your...

  • Page 52: Getting To Know Your Atv

    EBU15601 RIDE WITH CARE AND GOOD JUDGEMENT GETTING TO KNOW YOUR ATV Get training if you are inexperienced. This ATV is for recreation use. This section, Beginners should get training from a certified Riding your ATV, provides general ATV riding instructor.
  • Page 53 Riding your ATV requires skills acquired This ATV is designed to carry the operator through practice over a period of time. and cargo only - passengers prohibited. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Never carry a passenger.
  • Page 54 Apparel Always wear an approved helmet that fits prop- erly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants Never operate this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
  • Page 55 Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. 1. Protective clothing 2 Goggles 3. Gloves 4. Boots 5. Helmet Never consume alcohol or drugs before or while driving this ATV. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper...
  • Page 56 Do not operate at speeds too fast for your skills or the conditions. Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and Always go at a speed that is proper for the maintenance procedures schedules...
  • Page 57 This model also has an air intake restrictor plate to limit the amount of engine power available. Yamaha recommends that all beginners start off with the speed limiter turned in and the air intake restrictor plate installed to limit the amount of speed available while they learn.
  • Page 58 Loading and accessories During operation Use extra caution when riding the ATV with addi- Always keep your feet on the footboards during tional loads, such as accessories or cargo. The operation. Otherwise your feet may contact the ATV’s handling may be adversely affected. rear wheels.
  • Page 59 Never attempt stunts, such as wheelies or and accessories added to this vehicle should jumps. Don’t try to show off. be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions.

  • Page 60: Be Careful Where You Ride

    Exhaust system BE CAREFUL WHERE YOU RIDE The exhaust system on the ATV is very hot dur- ing and following operation. To prevent burns, This ATV is designed for off-road use only. avoid touching the exhaust system. Park the Riding on paved surfaces can cause loss of con- ATV in a place where pedestrians or children trol.
  • Page 61 While riding on unpaved public streets or roads Know the terrain where you ride. may be legal in your area, such operation can Ride cautiously in unfamiliar areas. Stay alert for increase the risk of collision with other vehicles. holes, rocks, or roots in the terrain, and other Watch carefully for other vehicles.
  • Page 62 When riding in an area where you might not easily be seen, such as desert terrain, mount a Do not operate on excessively rough, slip- caution flag on the ATV. DO NOT use the flag pery or loose terrain until you have learned pole bracket as a trailer hitch.
  • Page 63 Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV, be sure not to accidentally move the shift pedal. Remember that the engine and exhaust pipe will be hot when riding and afterwards;...
  • Page 64 Be sure to coordinate the use of the throttle and As you slow down, shift to a lower gear. Be sure shift pedal properly. If the throttle is applied too that the engine has sufficiently slowed before abruptly or if the throttle is not released during engaging a lower gear.

  • Page 65: Turning Your Atv

    TURNING YOUR ATV As you approach a curve, slow down and begin To achieve maximum traction while riding off- to turn the handlebars in the desired direction. road, the two rear wheels are mounted solidly As you do so, put your weight on the footboard on one axle and turn together at the same to the outside of the turn (opposite your desired speed.

  • Page 66: Climbing Uphill

    CLIMBING UPHILL This procedure should be practiced at slow Use proper riding techniques to avoid vehicle speed many times in a large off-road area with overturns on hills. Be sure that you can maneu- no obstacles. If an incorrect technique is used, ver your ATV well on flat ground before attempt- your ATV may continue to go straight.
  • Page 67 If you are climbing a hill and you find that you have not properly judged your ability to make it 8 Always follow proper procedures for climbing hills as described in this Owner’s to the top, you should turn the ATV around while Manual.
  • Page 68 Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: 8 Keep weight uphill. 8 Apply the brakes. 8 Lock the parking brake after you are stopped. If your ATV has stalled or stopped and you If you begin rolling backwards: believe you can continue up the hill, restart care- 8 Keep weight uphill.

  • Page 69: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you.

  • Page 70: Crossing A Slope

    CROSSING A SLOPE Traversing a sloping surface on your ATV Always follow proper procedures for going requires you to properly position your weight to down hills as described in this Owner’s maintain proper balance. Be sure that you have Manual. learned the basic riding skills on flat ground Note: a special technique is required when before attempting to cross a sloping surface.

  • Page 71: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, Never attempt to turn the ATV around on any shallow water of up to a maximum of 20 cm in hill until you have mastered the turning tech- depth.
  • Page 72 After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy condi- tions.

  • Page 73: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN SLIDING AND SKIDDING Riding over rough terrain should be done with Care should be used when riding on loose or caution. Look out for obstacles which could slippery surfaces since the ATV may slide. If cause damage to the ATV or could lead to an unexpected and uncorrected, sliding could lead upset or accident.
  • Page 74 If the rear wheels of your ATV start to slide side- With practice, over a period of time, skill at con- ways, control can usually be regained (if there is trolled sliding can be developed. The terrain room to do so) by steering in the direction of the should be chosen carefully before attempting slide.

  • Page 75: What To Do If

    WHAT TO DO IF ... 8 If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have only. Be sure to read each section on riding the room.
  • Page 76 8 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 77: Periodic Maintenance And Adjustment

    Electrical compo- 3. Owner’s tool kit nents can cause shocks or can start fires. Turn off the engine when performing mainte- nance unless otherwise specified. Have a Yamaha dealer perform service if you are not familiar with machine service.
  • Page 78 If you have ques- If you do not have a torque wrench available tions, consult an authorized Yamaha ATV during a service operation requiring one, take dealer. your machine to a Yamaha dealer to check the torque settings and adjust them as necessary.

  • Page 79: Periodic Maintenance/Lubrication

    EBU02621 PERIODIC MAINTENANCE/LUBRICATION NOTE: 8 For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. 8 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
  • Page 80 Fittings and fasteners* 9 Correct if necessary. 9 Check specific gravity. 9 Check breather hose for correct routing. Battery* 9 Correct if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 81: Engine Oil

    EBU14181 Engine oil Engine oil level measurement 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in.
  • Page 82 Engine oil replacement 7. Fill the engine with oil and install the dip- 1. Place the ATV on a level surface. stick. 2. Warm up the engine for several minutes and stop it. Recommended oil type: 3. Place a container under the engine. 20W50, 20W40, 15W40, 10W40, 4.

  • Page 83: Final Gear Oil

    EBU00869 Final gear oil Final gear oil measurement 1. Place the ATV on a level surface. 2. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. 3. Remove the dipstick and inspect the oil 1.
  • Page 84 Final gear oil replacement 5. Fill the final gear case with oil. 1. Place the ATV on a level place. Recommended oil: 2. Place a container under the final gear SAE80API “GL-4” Hypoid gear oil case. 3. Remove the dipstick and drain bolt to drain Oil quantity: the oil.

  • Page 85: Spark Plug Inspection

    Do not 0.6–0.7 mm attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 86: Cleaning The Air Filter Element

    EBU15621 When installing the spark plug, always clean the Cleaning the air filter element gasket surface and its mating surface. Wipe off NOTE: any grime from the threads and tighten it to the There is a check hose at the bottom of the air fil- specified torque.
  • Page 87 1. Remove the quick fasteners. 2. Remove the front cover by sliding it down- ward and pulling it off as shown. 1. Air filter case cover 2. Fastener (×4) 3. Remove the air filter case cover by unhooking the fasteners. 1.
  • Page 88 4. Remove the air filter element by unhooking NOTE: the fastener. The air filter element should be wet but not drip- 5. Wash the air filter element gently but thor- ping. oughly in solvent. 9. Install the air filter element. Always use parts cleaning solvent to clean 10.

  • Page 89: Air Intake Restrictor Plate Removal

    Never operate the engine with the air filter element removed. This will allow unfiltered air to enter the engine, causing rapid engine wear possible engine damage. Additionally, operation without the filter ele- ment will affect carburetor jetting with sub- sequent poor performance and possible engine overheating.

  • Page 90: Carburetor Adjustment

    NOTE: requires very sophisticated adjustment. Most A diagnostic tachometer must be used for this adjusting should be left to a Yamaha dealer who procedure. has the professional knowledge and experience to do so. However, the idling speed may be per- 1.

  • Page 91: Valve Clearance Adjustment

    The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. 1. Throttle stop screw EBU00304...

  • Page 92: Front And Rear Brake Shoe Inspection

    Apply the brake and check the position of the indicator. If the indicator reaches the wear limit line or mark, ask a Yamaha dealer to replace the shoes 1. Wear limit mark 2. Wear indicator as a set.

  • Page 93: Front Brake Lever Free Play Adjustment

    1. Loosen the upper locknut and fully turn in EBU00324 Front brake lever free play adjustment the adjusting bolt. 2. Loosen the lower locknut. NOTE: 3. Turn the lower adjusting bolt until specified Before adjusting the brake, inspect the front free play is obtained.
  • Page 94 8 Make sure the brakes do not drag. Replacement of brake components requires a’ professional knowledge. These procedures should be performed by a Yamaha dealer. 1. Cable joint 6. Tighten the upper locknut. 8-18...

  • Page 95: Rear Brake Lever And Pedal Adjustment

    EBU03361 NOTE: Rear brake lever and brake pedal adjustment If specified free play cannot be obtained, tighten Brake lever free play adjustment the brake cable adjusting nut at the rear wheel 1. Loosen the brake cable locknut. hub until brake lever free play is 5–8 mm. 2.
  • Page 96 8 Make sure the brakes do not drag. 8 Replacement brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. a. Free play 1. Brake rod adjusting nut 8-20...

  • Page 97: Adjusting The Clutch

    EBU15631 Adjusting the clutch 1. Remove the left footboard by removing the screws and bolts. 1. Rubber cap 2. Locknut 3. Adjusting bolt 5. Tighten the locknut to the specified torque. Tightening torque: 1. Footboard 2. Screw (×6) 3. Bolt (×2) 8 Nm (0.8 m0kgf) 2.

  • Page 98: Cable Inspection And Lubrication

    (all-purpose grease) restricted, which could cause an accident or injury. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Engine oil 1. Grease nipple 8-22...

  • Page 99: Wheel Removal

    EBU01112 EBU00871 Wheel removal Wheel installation 1. Loosen the wheel nuts. When installing the wheels, reverse the removal 2. Elevate the ATV and place a suitable stand procedure. under the frame. Tighten the wheel nuts to the specified torque. 3. Remove the nuts from the wheel. Tightening torque: 4.

  • Page 100: Battery

    EBU00379 Battery Check the level of the battery fluid and see if the Battery electrolyte is poisonous and danger- terminals are tight. Add distilled water if the fluid ous, causing severe burns, etc. It contains level is low. sulfuric acid. Avoid contact with skin, eyes or clothing.

  • Page 101: Replenishing The Battery Fluid

    EBU11950 Replenishing the battery fluid Normal tap water contains minerals which A poorly maintained battery will corrode and dis- are harmful to a battery. Therefore, refill only charge quickly. The battery fluid should be with distilled water. checked at least once a month. 1.

  • Page 102: Fuse Replacement

    Then turn on the switches. If fire. the fuse immediately blows again, consult a Yamaha dealer. Specified fuse: 5 A To prevent accidental short-circuiting, turn off the main switch when checking or replac- ing a fuse.

  • Page 103: Troubleshooting

    Use only gen- uine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a short- er service life and can lead to expensive repair bills.

  • Page 104: Troubleshooting Chart

    2. Compression Use electric starter There is compresson Compression normal to see if there is compression No compression Ask a Yamaha dealer to inspect Wipe clean with dry 3. Ignition cloth Remove spark Spark good Ignition system normal plug and check...

  • Page 105: Cleaning And Storage

    EBU00420 3. Rinse the dirt and degreaser off with a gar- CLEANING AND STORAGE den hose. Use only enough pressure to do the job. A. CLEANING Frequent, thorough cleaning of your machine Excessive water pressure may cause water will not only enhance its appearance but will seepage and deterioration of wheel bearings, improve its general performance and extend the brakes, transmission seals and electrical...

  • Page 106: Storage

    NOTE: idle for several minutes. Use of fuel stabilizer eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system is to be drained instead. 2. Remove the spark plug, pour about one Wet brakes may have reduced stopping abili- tablespoon of SAE 10W30 or 20W40 ty, increasing the chance of an accident.
  • Page 107 4. Block up the frame to raise all wheels off the ground. 5. Tie a plastic bag over the exhaust pipe out- let to prevent moisture from entering. 6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil.

  • Page 108: Specifications

    EBU00428 SPECIFICATIONS Model YFM80G Dimensions: Overall length 1,550 mm Overall width 855 mm Overall height 930 mm Seat height 665 mm Wheelbase 1,030 mm Ground clearance 100 mm Minimum turning radius 2,400 mm Basic weight: With oil and full fuel tank 124 kg Engine: Type...
  • Page 109 MODEL YFM80G Engine oil: –20° –10° 0° 10° 20° 30° 40° 50°C Type 5W30 10W30 10W40 15W40 20W40 20W50 Recommended engine oil classification: API Service SE, SF, SG type or higher In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
  • Page 110 Model YFM80G Final gear oil: Type SAE 80API “GL-4” Hypoid gear oil Quantity: Total amount 0.12 L Air filter: Wet type element Fuel: Type Unleaded gasoline only Tank capacity 6.8 L Reserve amount 0.9 L Carburetor: Type/manufacturer VM16SH/MIKUNI Spark plug: Type/manufacturer CR7HSA/NGK 0.6–0.7 mm...
  • Page 111 Model YFM80G Transmission: Primary reduction system Spur gear Primary reduction ratio 65/20 (3.250) Secondary reduction system Shaft drive 19/18 × 34/10 (3.588) Secondary reduction ratio Transmission type Constant mesh 3-speed Operation Left foot operation Gear ratio: 39/11 (3.545) 35/17 (2.059) 31/22 (1.409) Chassis: Frame type...
  • Page 112 Model YFM80G Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Left hand and right foot operation Suspension: Front Leading arm Rear Swingarm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Wheel travel: Front wheel travel 57 mm...

  • Page 113: Conversion Table

    EBU01070 Conversion table All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit values to IMPERIAL unit values. Example: METRIC CONVERSION IMPERIAL VALUE FACTOR VALUE × 0.03937 2 mm 0.08 in Conversion table METRIC SYSTEM TO IMPERIAL SYSTEM Conversion...
  • Page 116 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2005.3-0.1x1 !

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